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Agglomeration Seminar NyKoSi
EURAGGLO – KOMAREK ROLLER PRESSES:
Applications in the fields of carbon, metallurgy and steel-mills
22-23 November, 2016Trondheim – NORWAY
Agglomeration
Process consisting in particles size enlargement carried out on finely divided solids with the use of pressure, agitation or heat.
Granulation
Agglomeration of a finely divided solid into granules of varioussizes by a process involving agitation (WET GRANULATION). This word also applies to COMPACTION-GRANULATION process usingpressure (dry granulation).
Introduction
Agglomerate and granulate
The different bond types in the agglomeration processes
The different agglomeration processes1. Processes using agitation or « snow balling » effect in wet conditions without theuse of external forces or pressure
Agitation agglomeration
• Pelletizing discs or deep drums• Granulation drums• Mixers-granulators• Fluidized beds• Atomizers
WET PROCESSES
2.Processes using pressure with weak, average or high external forces.
Pressure agglomeration
• Roller presses or compactors
• Flat ot circular die pellet presses• Hydraulic presses• Tabletting presses
DRY OR SEMI-WET PROCESSES
The different agglomeration processes
Pressure Agglomeration
APPLICATIONS IN THE CARBON AREA
• Low-rank coals- Binderless briquetting for transport to power plants
• Anthracite mixes- Home heating• Iron ore or other metallic oxides with carbon to feed
furnaces• Specific high volatiles low ash coals for activation• Blends of non-coking + coking coals to feed coke plants• Charcoal briquetting to produce barbecue briquette,
activated carbon, serve as reducer in metallurgical plants(alone or in addition to metallic oxides…)
• Carbon (coke, anthracite…) mixed to millscales for recycling
Delivery of Low Rank Coal Based Energy
Drying & Binderless Briquetting of LRC
Drying & Binderless Briquetting of LRC
Dried and Briquetted Low Rank Coal with High Heating Value
Requirements for carbon-based rawmaterials for briquetting
•Size range•Moisture content•Hardness / wettability•Shape of particles
Choice of binders for carbon briquetting
• Price• Availability• Environmental aspects• Process complexity• Final use of briquettes
Binderless briquetting is only used for specific coalswith very particular maceral analyses, mostly fromthe sub-bitumonous or bituminous families.
Coal Briquetting Possible ProcessesBinder
• Resin + hardener + green strength additive (GSA)
• Molasses + Hydrated lime
• Molasses +Phosphoric Acid + GSA
• Lignosulfonate
• Starch (with or without additive)
• Bitumen, pitch
+• Cold cure system • No requirement for heat treatment
• Cold cure system (but might require some heat after briquetting)
• Low cost binder
• Good end briquettes
• Can be cold used with additives...• Very good end briquettes
• Easy to use binder
• Very good waterproof briquettes
-• Smell upon ignition
• Poor waterproof properties unless coated
• Smell upon burning
• Require post-treatment for curing
• But generally need a post treatment
• Sulfur addition
• Require post treatment for drying/curing
• Aromatic content if not cured after briquetting
• Health issues around use of these binders in a plant
Example of Euragglo design capability:A petroleum coke briquetting plant
• Capacity: 40 MTPH• Construction in 2008/2009• Installed in Navodari-Romania
Flow Diagram
General Lay-Out
Typical ProcessFlow-diagram
Coal BriquettingLime/Molasses
Typical ProcessFlow-diagram
Coal BriquettingBitumen
A Coal BriquettingUnit
Drying and Briquetting
Zones
The feeding and drying zones
The drying zone
The mixing
The roller press
Press DH500Capacity: 50 MTPH of coal briquettes
Main Applications of Roller-Press Briquettingfor Steel-Mill By-products
Mill scalesDried sludges
Filter dust (EAF..)Steel gritsDRI fines
Crushed spent refractories
All fines and dusts of raw materials can generally be briquetted with a binder, provided they are dried to a moisture content below 2% and with a
controlled amount of free quick lime (CaO)
Recycling Steel Mill Waste to Recover ValuableIron
By-products in the steel-mill area
Briquetting: one example
Process of Waste Iron Oxide Briquetting
Typical Feed and Product Specifications
Agglomeration of steel-mill by-productsMain parts of the briquetting plant:- The preparation of the raw materials including eventual
drying, hydration of lime, crushing, dosing..- The storage and dosing of the binders (generally molasses,
hydrated lime, lignosulphonates, cold cured binders..)- The mixing unit (batch ot continuous) - The briquetting unit with the screening of the briquettes- The storage of briquettes for the curing before use
Example of briquetting unit 10 T/h (Spain)
Example of briquetting
unit
Arcelor Mittal - FRANCE
Recycling of EAF Dust with RHF to Recover Zinc Oxide-ZincOx Recycling Plant in South Korea
View of roller press
Waste oxidebriquettes
Example of 35 MTPH briquetting plant for dried sludges
Arcelor Mittal France
• Batch mixing :sludges and other by-products• Binder: Molasse + Lime (+ cement)• Press type DH450-36
– Roll diameter: 915 mm– Roll width: 385 mm– Gravity feed– Total force : 200 Tonnes
Briquetting PressDH450-36
Pockets in Briquetting
rolls
Segmented tyres
Segmented Tyres
Various PressRollers
HARSCOCORUS TATAScunthorpe UK
HARSCOCORUS TATAScunthorpe UK
Main applications of roller-press briquetting for the metallurgical area
• Metallic ores + oxides (Chromite, manganeseore, copper concentrates, nickel …)
• Metal fines (nickel, chromium, cobalt …)• Ferro alloys (FeMn, FeCr, FeSi, SiMn..)• Silicon carbide• Lime/Dololime + additives (Al, Fe..)
Example: Agglomeration of Nickel Laterite
Main parts of the briquetting plant:• The preparation of the raw materials including
eventual drying, crushing, dosing• The mixing unit, batch or continuous (coal, dust,
recycling, recipe of laterite)• The briquetting unit with the screening of the
briquettes• The storage of briquettes before use (if needed)
Example of a Multiple-press PlantNickel Laterite
Nickel Laterite
Example of a Multiple-press
Plant
Euragglo – KomarekRoller - Presses
Key points:• Stability of raw materials is key to success of briquetting/granulation
plants (size-range, moisture content…)• Choice of binders (technical + economic) will influence choice of
adequate mixing system• R&D steps before plant selection are key to understand raw material
behaviour during agglomeration process and mechanical characteristicsof finished agglomerates
• Large range of presses/compactors is necessary to cover requirementsin terms of capacity (Lab, Scale-up industrial, industrial..), feed method(to the rolls), required briquetting/compaction force, etc..
K.R. KOMAREK GROUPEURAGGLO
Worlwide capabilities
• R&D in pilot plants (USA, France, Argentina, Australia, South Africa)• Audit of existing plants to improve process and/or maintenance• Engineering of briquetting and granulation system• Large know-how based on many industrial references
Briquetting and Granulation specialists